A PROJECT REPORT

ON
FLYASH

In Partial Fulfillment for the Award of

Bachelor of Technology
Degree Of
Rajasthan Technical University, KOTA

2014-2015
Submitted by: -

ABHIJEET PARASHAR
RAVI PRAKASH SWAMI
BHARAT BHUSHAN PIPLIWAL

ACKNOWLEDGEMENT

We thank the Head of the Department of CIVIL ENGINEERING(CE), Prof. Dr .D.K SHARMA for
cooperating us for making this project.Our special thanks go to the Principal, GRIET, Prof., for
giving us such a wonderful opportunity to do this project.Without these people, it wouldnt
have been possible to do this project on ROLE OF FLY-ASH BRICKS IN CONSTRUCTION.

ABHIJEET PARASHAR
RAVI PRAKASH SWAMI
BHARAT BHUSHAN

ABSTRACT

Fly ash is a fused residue of clay minerals present in coal. The high temperature generated
when coal burns in thermal power plants, transforms the clay minerals in coal powder into a
variety of fused fine particles of mainly aluminium silicate composition.

Pulverized fuel ash commonly known as fly ash. It is a useful by-product from
thermal power stations using pulverized coal as fuel and has considerable pozzolonic activity.
This national resource has been gainfully utilized for manufacture of fly ash-lime bricks as a
supplement to common burnt clay buildings bricks leading to the conservation of natural
resources and improvement in environment quality.
Fly ash-lime bricks are obtained from materials consisting of pulverized fly ash in
major quantity, lime and an accelerator acting as a catalyst. Fly ash-lime bricks are generally
manufactured by intergrading blending various raw materials are then moulded into bricks and
subjected to curing cycles at different temperatures and pressures. On occasion as and when
required, crushed bottom fuel ash or sand is also used in the composition of the raw material.
Crushed bottom fuel ash or sand is also used in the composition as a coarser material to control
water absorption in the final product. Fly ash reacts with lime in presence of moisture from a
calcium hydrate which is a binder material. Thus fly ash lime in presence of moisture form a
calcium silicate hydrate which is binder material. Thus fly ash lime brick is a chemically
ended bricks.
These bricks are suitable for use in masonry construction just like
common burnt clay bricks.

CONTENTS
1. INTRODUCTION
1.1 General
1.2 Utilization of fly ash in cement and bricks
1.3 Fly ash production
1.4 scope and objectives

2. LITERATURE REVIEW
2.1 General
2.2 Characteristics of fly ash
2.2.1 Physical Properties Of Fly Ash
2.2.2 Chemical Compositions Of Fly Ash
2.2.3 Mineralogy of Fly Ash
2.2.4 Reactivity
2.3 Classification of Fly Ash
2.4 Fly Ash utilization
3. FLY ASH BUILDING BLOCKS/BRICKS
3.1 Raw Materials Required
3.1.1 Fly Ash (pulverized fuel ash)
3.1.2 Lime
3.1.3 Gypsum
3.1.4 Sand
3.1.5 Water
3.2 Types of Fly Ash Bricks

3.3 Market Demand

4. METHODOLOGY
4.1 Manufacturing process of bricks
4.2 Characteristics of Fly Ash Bricks
4.3 Technical Specifications
4.4 Comparison of normal clay bricks and Fly ash bricks
4.6 Fly Ash Brick Site Visit
4.7 Brick making machines
4.8 Advantages & Disadvantages
4.9 Uses
5. TEST RESULTS AND DISCUSSION

5.1 General
5.2 Test results
5.2.1 WATER ABSORBTION TEST
5.2.2 COMPRESSIVE STRENGTH TEST

6. CONCLUSION
7. BIBILOGRAPH

INTRODUCTION
1.1 GENERAL
Fly ash brick First invented in 2007.....
American civil engineer Henry liu announced the invention of a new type of fly ash brick in
2007. Liuss brick is compressed of at 4,ooo psi and cured for 24 hrs in a 150 F(66 C) steam
bath, then toughened with air entrainment agent , so that it lasts for more than 100freeze
thaw cycles. Owing to high concentration of calcium in class c fly ash , the brick can be
described as self cementing. Since method contains no clay and uses pressure instead of heat ,it
saves energy, reduces mercury pollution,costs 20% less than traditional manufacturing
techniques. This type of brick is now manufactured under license in USA.
Fly ash bricks are constructed at least partially from the residue of burnt coal
.Depending on the type of coal that is burned, the resulting fly ash can take a number of
different forms. Some kinds of fly ash require a cementing agent, such as quicklime or Portland
cement . Other types contain a large enough percentage of lime that they are self setting,
requiring only the addition of water to be turned into fly ash bricks. These bricks have been
utilized in construction since the 1950s in some parts of the world, and in certain configurations
are able to meet or exceed specifications for clay or cement bricks.
When coal is burned, one of the results is a fine powder known as fly ash. While other
ashes might settle at the base of the furnace where the coal is being burned, fly ash is light and
fine enough that flue gases often are able to carry it up through the chimney. In the past, this
ash was typically allowed to escape into the atmosphere, though in many locations
environmental regulations the fly ash must be captured for safe disposal or reuse. Since toxic
materials like mercury and lead may be highly concentrated in fly ash, this can lead to
environmental or health concerns.

1.2 UTILISATION OF FLY ASH IN CEMENT AND BRICKS

It has been above 70 years to research and use fly ash. With its application, the action
mechanism of fly ash had been recognized. During the initial stage, only its pozzolanic activity is
paid attention [ 8 and 9]. Many researchers devoted themselves to the research of the potential
activity of fly ash and the hydration process of fly ash cement. With the deepening of the
cognition for fly ash properties, some people found that the particles of fly ash have the
morphology that is different to other pozzolanic materials. It is the unique particle morphology
to make it have the ability reducing water, which other pozzolanic materials do not have [ 10,
11, 12 and 13 ]. and In 1981, Yinji [ 15 ] and Danshen [ 16 ] summarized the previous research
results and put forward the hypothesis of "fly ash effects." They considered that fly ash has
three effects in concrete, i.e., morphological, activated and micro aggregate effects. The three
effects are relative each other. This shows that the morphological effect is the important aspect
of fly ash effects.

1.3 Fly Ash Production

In each country utilization of fly ash depends on the local condition and has much to
do with the fact that fly ash is multifunctional material and can be used for various purposes. In
the building industry fly ash can be used in different ways for different products. In concrete fly
ash can be used as partially replacement of cement and/or sand to enhance workability of fresh
concrete, to reduce heat of hydration and to improve concrete impermeability and resistance
to sulfate attack.The properties of fly ash are varying depending on the coal kind and origin and
on the power plant mode of operation. In certain uses some kind of beneficiation is required,
either to improve its properties for the specific use or to achieve homogeneity. In concrete, fly
ash can actually be used also "as is" when its properties fall within certain limits, but
classification by particle size and/or control of the unburned coal greatly enhance the beneficial
effects of the fly ash and of course its commercial value.
Utilization of fly ash ranged between 3-5% in the late 1980s and early 1990s. There
was no large-scale concerted effort for promoting fly ash utilization. Technologies and research
were generally isolated with little emphasis on commercialization. Although attempts were
made to use of fly ash in manufacturing bricks, cellular concrete, prefab items, and cement as
well as for reclamation of low lying areas and construction of roads, the desired impact could
not be achieved.

Table 1 Fly ash production and utilization

S.NO

ZONE NAME

FA GENERATION

UTILIZATIONS

UTILIZATIONS

(Million tones)

(Million tones)

(%)

1.

SOUTHERN

13.5

0.8

2.

WESTERN

16.5

0.8

3.

EASTERN

10.21

2.94

28.8

4.

NORTHERN

15.5

2.3

14.8

6.84

54.6

TORAL

55.71

(ALL INDIA)

The minimum and maximum percentages of fly ash in PPC, specified by IS 456, have risen from
10% to 15% and from 25% to 35% respectively. The government of India has issued a notification
that makes it mandatory to use at least 25% ash in the manufacture of clay bricks, blocks, or tiles
within a radius of 50 km from coal or lignite based thermal power plants.

1.4 SCOPE AND OBJECTIVE OF STUDY

The relationship of fly ash bricks to construction sector, in the context of fly ash generation by
coal based thermal power plants.The present status of fly ash brick manufacture in India,
availability of fly ash, and potential of utilization of fly ash bricks.
Status of fly ash brick technologies in India by way of research work being done by
various institutions, and technologies being used for manufacture of these bricks. Keeping in
view, the technological status for fly ash brick manufacture, assessment of the technologies for
its relevance and suitability, keeping in view material inputs required, energy requirements,
costs, infrastructure requirements etc. It may also be noted that various cements and mixes
which can be made using fly ash, have the potential become raw materials for fly ash bricks and
blocks of various specifications. Therefore, this aspect has also been discussed.Utilization of fly
ash can result not only in reducing the magnitude of the environmental problems, but it is also
to exploit fly ash as raw material for value added products (and conserve traditional materials),
and for extraction of valuable materials. Amongst many uses that fly ash can be put to, that in
building materials is particularly suitable. It is also anticipated, that there would be considerable
short-fall in production of various building materials. According to a study, there would be a
large short-fall in the production of bricks to the tune of 25 billion bricks on an estimated
demand of 100 billion bricks per year in India by the turn of the century.

2. LITERATURE REVIEW

2.1

GENERAL

Fly ashes from Vijayawada thermal power plants were used in the experiments of the present
study. A brief review of literature about the physical and chemical properties; mineralogy and
morphology behavior of fly ashes is presented. Literatures regarding concrete applications of fly
ashes have been used in construction are also discussed.
Fly ash is produced from burning of pulverized coal in thermal power plants. The
pulverized coal is fed into the boilers and burnt with the supply of additional air. The
temperature in the boiler exceeds 1600 C and the most of the mineral matter present in the
coal are fused and altered physically and chemically. The resulting residue is called coal
combustion by-products namely bottom ash, economizer ash, air pre-heater ash, and
electrostatic precipitator ash (fly ash). These ashes are handled and disposed off separately
owing to their differing qualities by mechanical, hydraulic and pneumatic conveying systems.
The quality of ash produced is dependent on various factors like source coal and its degree of
pulverization, design of furnace, changes in coal supply, changes in boiler load, and firing
condition. Because of this inherent variability of the material, it is necessary to study the
characteristics and engineering behavior of fly ash in detail before its use in an application.

2.2

CHARACTERISTICS OF FLY ASH

As per ASTM C 618 1993[17], there are two classes of fly ash namely class F and class C. Class
F fly ash is produced from burning anthracite or bituminous coal and is pozzolanic in nature and
class C is obtained from lignite or sub-bituminous coal. Class C fly ash possesses both pozzolanic
and self-hardening property. Hence, it is necessary to characterize the material scientifically to
utilize it in different applications.

2.2.1 Physical Properties Of Fly Ash

The specific gravity, loss on ignition and specific surface area are the prominent physical
properties of fly ashes. The specific gravity of fly ash may vary from 1.3 to 4.8 . The iron oxide
content plays a decisive role in the specific gravity of the material. The specific gravity is more
for fly ashes containing more iron oxide and vice versa. The presence of opaque spherical
magnetite and hematite particles in sufficient quantity will increase the value of specific gravity
to about 3.6 to 4.8. On the other hand, as the amount of quartz and mullite increases, the
specific gravity decreases. However, coal particles with some minerallic impurities will have
lower specific gravity in the range 1.3 to 1.6. The range of specific gravity of Canadian fly ashes
is reported to be in the range of 1.91 to 2.94 and that of American fly ashes in the range of 2.14
to 2.69.

2.2.2 Chemical Compositions Of Fly Ash

The main chemical compounds of class F fly ash are silica, alumina and iron oxide. Other minor
constituents include oxides of calcium, magnesium, titanium, sulphur, sodium and potassium.
Class C fly ash contains relatively higher proportion of calcium oxide and lesser proportion of
silica, alumina and iron oxide than class F flyash.

2.2.4 Mineralogy of Fly Ash

Fly ash consists of both crystalline and amorphous phases. The crystalline phases could be
quartz, mullite, silimanite, crystallite, cristobalite, sulphates of iron, magnetite etc. The
amorphous phases could be of silica and silicates predominantly of aluminium but containing
calcium, magnesium, and iron in varying concentration with and without traces of sodium and
potassium. The reactivity of fly ashes depends on the non crystalline or glass content in it. The
chemical composition of the glass in the high calcium fly ash is different from the low calcium
fly ash and hence the reactivity of both the ashes are different. The high calcium fly ashes are
more reactive than low calcium fly ashes. Diamond (1986)[20] and Mehta (1998)[19] pointed
out that the composition of glass in low calcium fly ashes is different from high calcium fly
ashes. American fly ashes contained magnetite and hematite in large proportions. The range of
quantitative measurement in British fly ashes was quartz (1-6.5%); mullite (935%); magnetite
and hematite (5% or less). For American fly ashes the proportions were quartz (0 - 4%); mullite
(016%); magnetite (030%); and hematite (18%). The glass proportions in these fly ashes
were found to range from 50 to 90%.The range of quantitative measurement in British fly ashes
was quartz (1-6.5%); mullite (935%); magnetite and hematite (5% or less). For American

flyashes the proportions were quartz (0 - 4%); mullite (016%); magnetite (030%); and
hematite (18%). The glass proportions in these fly ashes were found to range from 50 to 90%..

2.2.4.1 Reactivity
It is generally agreed that the glass or non-crystalline constituent of Class F fly ash goes into
reaction with Ca(OH)2,which is added as lime or released from the hydration of portland
cement. However, there are many other factors that influence there activity and relative rates
of hydration such as fineness, particle shape, particle size distribution. Fly ash is generally
judged for its quality in terms of strength behaviour. This is studied for pozzolanic
characteristics in two approaches; lime reactivity strength(LRS) and pozzolanic activity index
(PAI). IS:3812-1981,accords two grades to fly ash based on LRS2. Grade I is identified with a
minimum 4 MPa LRS whereas fly ash with lower strength at 3 MPa is categorised as Grade II.
The same code has also specified replacement compressive strength(PAI) at 80 percent as
another yardstick. The LRS given forthese grades generally does not correlate with pozzolanic
activity index. It is observed that certain fly ashes registering low LRS prove better for PAI and
certain other fly ashes recording good LRS have shown lower PAI. Hence to as certain the
suitability of fly ash as supplement to cement,the reactivity study in terms of PAI is desirable.

2.3 CLASSIFICATION OF FLY ASH

FLY ASH: THE MODERN POZZOLON

Fly ash is comprised of the non-combustible mineral portion of coal consumed in a coal
fueled power plant. Fly ash particles are glassy, spherical shaped ball bearings typically
finer than cement particles that are collected from the combustion air-stream exiting the
power plant.

There are two basic types of fly ash:

A) Class F
B) Class C.
Both types react in concrete in similar ways. Both Class F and Class C fly ashes undergo a
pozzolanic reaction with the lime (calcium hydroxide) created by the hydration (chemical
reaction) of cement and water, to create the same binder (calcium silicate hydrate) as cement.
In addition, some Class C fly ashes may possess enough lime to be self- cementing, in addition
to the pozzolanic reaction with lime from cement hydration.

2.4 FLY ASH UTILIZATION

Several factors have impeded fly ash utilization in India, while it is being extensively used
globally. Coal-based thermal power stations have been operational for more than 50 years but
the concept of developing environment-friendly solutions for fly ash utilization is only about 15
years old. Overall fly ash utilization in India stands at a fairly low level of about 15 per cent of
the quantity generated. Various possibilities for its use are under research.

Among numerous factors that account for the low level of utilization, the chief factors are:
1.Poor understanding of the chemistry of fly ash and its derivatives for proper end Applications.
2. Absence of standards and specifications for fly ash products.
3. Lack of reliable quality assurance for fly ash products Poor public awareness about the
products and their performance.

Fly ash from coal-fired thermal power stations is an excellent potential raw material for the
manufacture of construction material like blended cement, fly ash bricks, mosaic tiles, blocks. It
also has other, high volume applications and can be used for paving roads, building
embankments, and mine fills.

3. FLY ASH BUILDING BLOCKS/BRICKS

3.1 General
Fly Ash bricks are alternative to burnt clay bricks in the construction sector in India.At this time
India is witnessing a new phase in development. With rapid economicgrowth and high rate of
urbanisation. Construction provides the direct means for thedevelopment, expansion,
improvement and maintenance of human settlements isparticular and economic growth in
general. Construction activity accounts for morethan 50% of the development outlays in India.
Building construction costs areincreasing at rates which are So per cent over inflation.

This is primarily due to the increase in the cost of basic building materials like
burntbrick, steel, cement, timber, etc. As a result, the cost of construction usingconventional
building materials and construction forms range from As. 40001- to As.6000/- per sqm even for
normal housing. Construction costs of this order is beyondthe affordable capacity of the
economically Weaker Section and Low Income Groupand a large cross section of the Middle
Income Groups, whose income levels have notincreased commensurately. This has become all
the more relevant in the macrocontext. due to the large volume of housing to be done in both
rural and urban areasand the limited resource of building materials and finance
available.According to the projections for the Ninth Five Year Plan, there will be a shortage of
6.6 million houses in urban areas and 12.76 million houses in the rural areas at the end of year
2001, inspite of all the Governmental efforts and resources.

3.1.1 Availability of Fly Ash

Total flyash generation in India from Thermal Power Plants is estimated at aboot 60 million
tonnes per year, which may increase to about 110 million tonnes per year by 2010 AD. India
utilize only 3-4% of the flyash generated as compared to more than 40% utilisation in Europe,
China and America etc. The Government has indicated a clear willingness to achieve 50% fIyash
utilization by the turn of the century at its enlarged level of 90 million tonnes per annum. In

India, from Rajasthan fly ash will be available from Kota Thermal Power Plant that is 15 years
old.It can also be obtained from the cities like Ahmadabad , Bikaner , Barmer etc.

3.2 Raw Materials Required

Fly Ash bricks are made of fly ash, lime, gypsum and sand stone and water . These can be
extensively used in all building constructional activities similar to that of common burnt clay
bricks. The fly ash bricks are comparatively lighter in weight and stronger than common
claybricks. Since fly ash is being accumulated as waste material in large quantity near
thermalpower plants and creating serious environmental pollutionproblems, its utilisation as
main raw material in the manufacture of bricks will not only create ample opportunities for its
proper and useful disposal but also help in environmental pollution control to a greater extent
in the surrounding areas of power plants

3.2.1 Fly Ash(pulverized fuel ash):

Flyash is a waste material from thermal power stations. About30 million tonnes of flyash is
produced annually from as manyas 63 thermal power stations in the country. This very fine
industrial waste not only causes environmental pollution butalso poses problem of disposal.
The need for scientific andpollution free disposal of flyash has become a compelling necessity.

Large variations in thegrading of flyash from different thermal power plants, non- availability of
flyash in dry form, absence of any organisedbuilding industry in the country, high initial
investment insetting up flyash based building material units, nonavailabilityof indigenous plants
and machinery for commercialproduction of building materials from flyash are amongthe major
hurdles in the production of different building products from Indian flyash.

3.2.2 Lime
Lime is truly a versatile material in building construction projects. Lime can be used to prepare
the construction site by stabilizing the soil or remediating brownfield sites. Lime can be used in
the construction of masonry systems as a component of mortar or the masonry unit. Exterior
(stucco) and interior plaster systems can also contain lime. Finally, the decorative finishes can
be created with lime washes.
Lime provides benefits in the plastic and hardened state to mortars and plasters. In the plastic
state, lime can enhance the workability and water retention of plasters and mortars. In the
hardened state, lime products react with carbon dioxide to regenerate calcium carbonate or
limestone. This is a slow, gradual process which increases the hardness of the finished surface
and allows for the healing of hairline cracks by a process called autogenous healing. Since initial
strength is needed in most applications, additives such as gypsum, cement or pozzollans are
mixed with lime in construction applications. Lime can react with pozzolanic materials in the
mortar or plaster to produce a cement-like product.

CRUSHER DUST : 0 6 mm

3.2.3 Gypsum

Gypsum is a very soft sulfate mineral composed of calcium sulfate dihydrate , with the chemical
formula CaSO 42H 2O . It is found in alabaster , a decorative stone used in Ancient Egypt . It is
the second softest mineral on the Mohs scale of mineral hardness . It forms as an evaporite
mineral and as a hydration product of anhydrite .

Gypsum is a common mineral, with thick and extensive evaporite beds in association with
sedimentary rocks . Deposits are known to occur in strata from as far back as the Archaean eon
. Gypsum is deposited from lake and sea water, as well as in hot springs , from volcanic vapors,
and sulfate solutions in veins . Hydrothermal anhydrite in veins is commonly hydrated to
gypsum by groundwater in near-surface exposures. It is often associated with the minerals
halite and sulfur . Gypsum is also formed as a by-product of sulfide oxidation , amongst others
by pyrite oxidation , when the sulfuric acid generated reacts with calcium carbonate . Its
presence indicates oxidizing conditions. Under reducing conditions, the sulfates it contains can
be reduced back to sulfide by sulfate reducing bacteria . Electric power stations burning coal
with flue gas desulfurization produce large quantities of gypsum as a byproduct from the
scrubbers. Calcium sulfate, commonly known as natural gypsum, is found in nature in different
forms, mainly as the dihydrate (CaSO 4 2H 2O) and anhydrite (CaSO 4). They are products of
partial or total evaporation of inland seas and lake. Both the dihydrate and the anhydrite occur
in nature in a variety of forms. The origin of gypsum, its genesis, varieties and properties are
discussed, and the focus is then on the most common binding material produced from it,
plaster of Paris ( -hemihydrate), known in France as pltre de Paris, in the USA as calcined
gypsum, and in Germany as Stuckgips. Details are given of the properties of gypsum paste
(setting, expansion, and adhesion) and of hardened gypsum (strength, bulk weight, thermal
expansion, volume and linear changes under humidity fluctuations, moisture absorption,
paintability, corrosivity, thermal and acoustic insulation behaviour, and fire resistance).

Natural River Sand was used which is locally available in Hyderabad region. The specific gravity
was found 2.57. Fineness Modulus is also determined using 10mm to 150 m and is found
2.972. The fineness modulus gives the idea about average size of ~ 29 ~ particles in the fine
aggregates. The value 2.972 indicates medium size sand. The details of sieve analysis are
presented in Table 3.1, and the grading curve is shown in With sieve analysis data and fineness
modulus value, sand is considered as zone II grading sand of IS: 383 1970, which is considered
as good fine aggregate for concrete production. The grading limits of zone II sand for fine
aggregates as per IS: 383-1970

Table 3.2.1: Grading limits of Fine Aggregates IS: 383-1970

IS SIEVE

Percentage passing by weight for

DESIGNATION Grading - I

Grading - II

Grading - III

Grading - IV

10 mm

100

100

100

100

4.75 mm

90-100

90-100

90-100

95-100

2.36 mm

60-95

75-100

85-100

95-100

1.18 mm

30-70

55-90

75-100

90-100

600 micron

15-34

35-59

60-79

80-100

300 micron

5-20

8-30

12-40

15-50

150 micron

0-10

0-10

0-10

0-15

Sand is an extremely needful material for the construction but this important material
must be purchased with all care and vigilance. Sand which is used in the construction
purpose must be clean, free from waste stones and impurities.

SAND:

3.2.5 Water
Ordinary tap water was used in the production of bricks. water is one of the most important
elements in construction but people still ignore quality aspect of this element.

The water is required for preparation of mortar, mixing of cement concrete and for curing work
etc during construction work. The quality and quantity of water has much effect on the strength
of mortar and cement in construction work.

Quality of Water :
The water used for mixing and curing should be clean and free from injurious quantities of
alkalis, acid, oils, salt, sugar, organic materials, vegetable growth and other substances that may
be deleterious to bricks, stone, concrete or steel. Potable water is generally considered
satisfactory for mixing. The pH value of water should be not less than 6.

Water Reducing Admixtures

The water reducer admixture improves workability of concrete/mortar for the same water
cement ratio. The determination of workability is an important factor in testing concrete
admixture. Rapid loss of workability occurs during first few minutes after mixing concrete and
gradual loss of workability takes place over a period from 15 to 60 minutes after mixing.

3.4 Types of Flyash Bricks

Fly ash bricks can be divided into the following types :

i) FAL-G (fly ash-lime-gypsum) Bricks:

Fly ash-lime-gypsum bricks/blocks technology has been developed successfully by National
Thermal PowerCorporation ( NTPC ), Bhanu International and Ahmadabad Electricity Company (
AEC ) for manufacturing bricks/blocks which can replace burnt clay bricks as walling material. It
is also known as Fly Ash-Lime-Gypsum (FaL-G)bricks. It is not a brand name but it is duct
name,christened to the mix for easy identification of its ingredients. Fal-G bricks and blocks are
manufactured without using thermal energy, in contrast to the sintering involved in the
production of clay bricks.

ii) Clay- Flyash Bricks :

Manufacturing process of clay flyash bricks by manual or extrusion process involves mixing of
flyash (60 %) with clay of moderate plasticity. The green bricks are dried under ambient
atmospheric conditions or in shed to equilibrium moisture level of below 3 percent. Dried bricks
are fired in traditional brick kilns at 1000 30 C with a soaking period of 5 7 hoursat
maturing temperature.

iii) Flyash Sand Lime Bricks :

In presence of moisture, fly ash reacts with lime at ordinary temperature and forms acompound
possessing cementitious properties. After reactions between lime andflyash,calcium silicate
hydrates are produced which are responsible for the highstrength of thecompound.This
processes involves homogeneous mixing of raw materials (generally fly ash,sandandlime),
moulding of bricks and then curing of the green bricks. Some technologies call for usage of
chemical accelerator like gypsum.

iv) Cold Bonded Lightweight Flyash Bricks, Blocks and Tiles:

The material can be produced in a variety of building blocks, bricks and tiles, depending onlocal
markets and regulations. Keraton consists of cheap and ubiquitous raw materials such asfly ash
and / or other waste materials. These materials are mixed and a cold bonding agent isadded.
The mixed raw material is cast in moulds, after which the moulds are processed in amicrowave
oven for transportation to the building site.

The products can be applied as a lightweight material in the house building industry and utility
building, such as stables, barns, garages, etc. A surface treatment or coating for coloring is
possible. Strong points are theability to use fly ash, the insulation properties and the production
flexibility.

v) Flux Bonded Flyash Bricks Blocks and Tiles:

The process is similar to the one in the conventional tile industry: fly ash is mixed with lessthan
10 % plastic clay and a few additives and tiles, bricks or blocks are pressed. Theseshapes are
fired in the range of 900C to 1000C to make the final product. More than 85% of flyash is
used in the process.

3.5 Market Demand

180 billion tones of common burnt clay bricks are consumed annually approximately 340 billion
tones of clay- about 5000 acres of top layer of soil dug out for bricks manufacture, soil erosion,
emission from coal burning or fire woods which causes deforestation are the serious problems
posed by brick industry. The above problems can be reduced some extent by using fly ash bricks
in dwelling units.Demand for dwelling units likely to raise to 80 million units by year 2015 for
lower middle and low income groups, involving an estimated investment 0f $670 billion,
according to the Associated chamber of commerce and industry. Demand for dwelling units will
further grow to 90 million by 2020,which would requires a minimum investment of $890billion.
The Indian housing sector at present faces a shortage of 20million dwelling units for its lower
middle and low income groups which will witness a spurt of about 22.5million dwelling units by
the end of Tenth plan period.

There is ample scope for fly ash brick and block units.
1. India ranks as one of the largest generators of fly ash in the world, mainly from its 80 plus
thermal power stations (TPS) widely distributed within the country. The low utilisation levels of
fly ash in civil engineering purposes & building components, currently is at 15% (2002-03) of the
total fly ash generated annually in India.
2. Research both in India and abroad has amply proved that the building components produced
using fly ash are competitive, both in quality and cost, as compared to traditional building
materials. A techno-feasible study on utilisation of fly ash as building material in major cities of
India, beginning with Hyderabad, initiative taken by BMTPC is laudable.

4. METHODOLOGY

Fly ash bricks are nowadays mostly used for construction and gaining its popularity over
builders and engineers because of its high strength, uniformity and less consumption of mortar
plastering. Above to this it is eco friendly bricks which saves environmental damage caused by
burnt clay bricks and saves top agricultural soil which was the main raw material in the burnt
clay bricks. 73% power generated in INDIA is from Thermal Power and 90% of it is coal based.
Ash content is 27% to 42% of the coal used.Increase in FLYASH generation has risen from 4
crore to 11crore ton in the last decade and will rise to 1100 crore ton in coming decade.

Approximately 10,000 hectares of top soil is being lost every year for brick manufacturing and
road construction. If we continue in this format, very soon, we will not have sufficient soil to
produce our minimum required food.

4.2 Manufacturing of Fly ash Bricks

For manufacturing Flyash bricks , most of the machine manufacturers suggest the following
two mixing ratio, you can choose profitable mixing ratio to survive in the market if you are
facing low availability of Flyash .At the same time you should maintain the quality too. The fly
ash bricks are comparatively lighter in weight and stronger than common clay bricks. Since fly
ash is being accumulated as waste material in large quantity near thermal power plants and
creating serious environmental pollution problems, its utilization as main raw material in the
manufacture of bricks will not only create ample opportunities for its proper and useful disposal
but also help in environmental pollution control to a greater extent in the surrounding areas of
power plants.

There are several techniques for manufacturing construction bricks from fly ash, producing a
wide variety of products.
One type of fly ash brick is manufactured by mixing fly ash with an equal amount of clay, then
firing in a kiln at about 1000 degrees C. This approach has the principal benefit of reducing the
amount of clay required.

 Another type of fly ash brick is made by mixing soil, plaster of paris, fly ash and water, and
allowing the mixture to dry. Because no heat is required, this technique reduces air pollution.
More modern manufacturing processes use a greater proportion of fly ash, and a high pressure
manufacturing technique, which produces high strength bricks with environmental benefits.

4.3 Characteristics of FlyAsh Bricks

The standard size of the brick is 230x110x70.
The bricks are manufactured and tested as per IS 12894-2002.
Fly ash bricks are sound, compact and uniform in shape, size and colour. Smooth rectangular
faces of the bricks are accompanied with sharp and square corners. Fly ash Bricks are available
in various colours and shapes. The above picture shows the bricks in dark peach colour with
three holes on it. These holes are used for grouting. The mortar is poured into these holes for
proper bonding in between the bricks .
They are free from visible cracks, warpage, flaws and organic matter.

 Economical & environment friendly.

28% lighter than ordinary clay bricks.
Compressive strength: 7.5N/mm2 on an average.
Water absorption: <8%.

4.4 Technical Specifications

(1) Fly Ash Brick Size Details :

Size :
[4 Inches ] :- 230 x 100 x 75 mm
:- 230 x 100 x 100 mm
Size :
[6 Inches ] :- 230 x 150 x 80 mm
:- 230 x 150 x 100 mm

(2) Density :

1700 Kg/m3
(3) Weight:

230x100x75 mm ( Weight about 4.75 to 5.00 kgs.approx )

230x150x75 mm ( Weight about 2.75 to 3.00 kgs.approx )
(4) Load Bearing Capacity:

More than 25% as compare to clay bricks

(5) Composition :

(i) Cement : Best Quality OPC 53 Grade Cement / Gypsum Powder,Lime Powder
(ii) Thermal Station Fly Ash
(iii) Crushed Sand / Stone Dust
(iv) Chemicals

(6) Thermal Conductivity :

0.90 1.05 W/m2 0 C

( 0.75 0.90 K cal/m2 hr 0C )

(7) Drying Shrinkage :

Maximum Average drying test shrinkage 0.035-0.04 %

(8) Brick Colour :-

Gray / Dark Gray

4.4 Comparison of normal clay bricks and Fly ash bricks

NORMAL CLAY BRICK

FLY ASH BRICKS

Varying colour as per soil

Uniform pleasing colour like cement

Uneven shape as hand made

Lightly bonded
Plastering required
Heavier in weight
Compressive strength
around 35 Kg/cm2
More porous

Uniform in shape and smooth in

finish
Dense composition
No plastering required
Lighter in weight

is Compressive strength is around 100

Kg/cm2
Less porous

Thermal
conductivity
1.25 1.35 W/m2 C
Water absorption 20-25%

Thermal
W/m2 C

conductivity

0.90-1.05

Water absorption 20-25%

4.6 Fly ash bricks plant visit

We have visited fly ash bricks plant which is located at near poornima university,
ramchandpura, jaipur

PLANT LOCATION:

Near Poornima University

map here of plant

Goner Road,
Ramchandpura,

Fig. 7 Fly ash bricks plant location

Jaipur -000000

Amit company is a good example of use of fly ash bricks in Jaipur. We also visited the
construction of hostel (Name of place which use these bricks) made for students beside the ,
where these bricks are being used.
On site, the engineer told the process of making the fly ash bricks. The material required for
making of fly ash bricks are used in this plant are fly ash taken from Power Plant (Kota), Lime
taken from Exel Crop. Ltd. (Jaipur), Gypsum purchased from Jaipur and Sand dust. The
proportion of these raw materials is generally in the ratio 50-60% of fly ash 10-20% lime, 05-

10% Gypsum and 15-20% sand, depending upon the quality of raw materials are used in this
plant.
In this plant, Fly ash bricks are made by mixing the ingredients (Fly ash + lime + gypsum + sand
dust) in the appropriate proportion using mechanical mixer with the addition of water. After
mixing, the mixture is conveyed through belt conveyor to the mechanical presses, in this paste
has been moulded to shape of brick by applying 70-80 tons load over the dye. The green bricks
are dried up under sun from 24 hours and 7 days curing for creating a good quality of fly ash
bricks.

4.7 BRICK MAKING MACHINE

The technology consist of regular mechanical type and hydraulic version. The hydraulic version
is latest and gives higher production output with minimal inputs like in labour and power. The
strength of bricks in hydraulic version is better than the others. It gives the pressure of 25 to 50
Ton in lieu of 15 ton in mechanical versions. Embossing the monogram of company on the
bricks is easy. Production is high. Continuous operation is possible.

1.Fly ash Brick making machine, vibrator, hydraulic power pack motor and Control panel

It is hydraulically operated automatic machine. The structure is capable of handling load up to

100 bar. Different size of mould can be fitted with machine. Embossing on brick is easy. It give
high production at minimal power loads. Circulated water cooling ensure longer operation.

2.Pan mixing machine with gear box and motor:

A mechanical sturdy constructed with heavy rollers to grind the raw materials efficiently. Drive
by worm reduction gear box. Easy unloading mechanism with proper door arrangements.

3.Belt conveyer system

A fabricated belt conveyer to take the raw materials of 1.5 tiem more than the capacity of
machines. The raw materials can regulated according to the requirements. Rubber with nylon
coated belts.

4.Hydraulic pallot trolley

The trolley capable of transporting maximum bricks to stocking area operated hydraulically,
which reduce the manpower and cracks of bricks. We in Agni Engg. & Industreis manufacturing
the following capacity machines

4.8 ADVANTAGES & DISADVANTAGES

i. Appearance
These bricks have a pleasing colour like cement, are uniform in shape and smooth in finish,
also,they require no plastering for building work. The bricks are of dense composition,
uniformly shaped with/without a frog, free from visible cracks, warp-age, organic matter,

pebbles and nodules of free lime. They are lighter in weight than ordinary clay bricks and less
porous too.
ii. Structural Capability
These bricks can provide advantages being available in several load-bearing grades, savings
inmortar plastering, and giving smart looking brickwork. High compressive strength eliminates
breakages/wastages during transport and handling, the cracking of plaster is reduced due to
lower thickness of joints and plaster and basic material of the bricks, which is more compatible
withcement mortar.
iii. Thermal properties
Thermal conductivity is 0.90-1.05 W/m2 C (20-30% less than those of concrete blocks). These
bricks do not absorb heat; they reflect heat and gives maximum light reflection without glare.
iv. Sound insulation
It provides an acceptable degree of sound insulation.
v. Fire and vermin resistance
Flyash bricks have a good fire rating. It has no problems of vermin attacks or infestation.

Disadvantages :
Actually, the disadvantages listed by some people about fly ash bricks are imaginary. But the
flyash bricks manufacturing process involves strong health hazard for the labors. The fly ash is a
very tiny particle and it penetrates in to lungs and cause serious health trouble to the labors
engaged in flyash bricks manufacturing process. So many reports have proved this dangerous
nature of fly ash, and still no awareness is created among the labours in the thermal power
plants, cement factories, Brick manufacturing units etc..

Fly ash causes severe pollution of air and water, and its disposal gobbles up large tracts of
land. Well-planned programs for proper management of fly ash are therefore being undertaken
to enhance the use of fly ash in various applications, so that our already perilously imbalanced
environment can be protected
Fly ash is one of the numerous substances that cause air, water and soil pollution, disrupt
ecological cycles and set off environmental hazards.
The combustion of powdered coal in thermal power plants produces fly ash.
The high temperature of burning coal turns the clay minerals present in the coal powder into
fused fine particles mainly comprising aluminium silicate. Fly ash produced thus possesses both
ceramic and pozzolanic properties.

 When pulverised coal is burnt to generate heat, the residue contains 80 per cent fly ash and
20 per cent bottom ash. The ash is carried away by flue gas collected at economiser, air preheater and ESP hoppers. Clinker type ash collected in the water-impounded hopper below the
boilers is called bottom ash.

4.9 USES:
Several factors have impeded fly ash utilization in India, while it is being extensively used
globally. Coal-based thermal power stations have been operational for more than 50 years but
the concept of developing environment-friendly solutions for fly ash utilization is only about 15
years old. Overall fly ash utilization in India stands at a fairly low level of about 15 per cent of
the quantity generated. Various possibilities for its use are under research.

Among numerous factors that account for the low level of utilization, the chief
factors are:

Poor understanding of the chemistry of fly ash and its derivatives for proper end applications
Absence of standards and specifications for fly ash products
Lack of reliable quality assurance for fly ash products Poor public awareness about the
products and their performance
Non-availability of dry fly ash collection facilities Easy availability of land with top soil at cheap
rates for manufacturing conventional bricks
Lack of proper coordination between thermal plants and ash users.
Fly ash utilization in the country is gaining momentum owing to the stringent regulations that
the MoEF has stipulated, as also to increased awareness about the benefits of using fly ash for
various products.
Fly ash from coal-fired thermal power stations is an excellent potential raw material for the
manufacture ofconstruction material like blended cement, fly ash bricks, mosaic tiles and
hollow blocks. It also has other, high volume applications and can be used for paving roads,
building embankments, and mine fills.

5. TEST RESULTS AND DISCUSSION:

5.1 General

The results of all the tests carried out on Fly ash bricks and also the technical aspects are
presented and discussed in this chapter.

5.2 TEST RESULTS :

5.2.1 WATER ABSORBTION TEST:

(24-hour Immersion Cold Water Test)
APPARATUS:
A sensitive balance capable of weighing within 0.1 percent of the mass of the
specimen and a ventilated oven.
PRECONDITIONING:
Dry the specimen in a ventilated oven at a temperature of 105 to 115 C till it attains
substantially constant mass. Cool the specimen to room temperature and obtain its weight
(M1). Specimen warm to touch shall not be used for the purpose.
PROCEDURE:
Immerse completely dried specimen in clean water at a temperature of 27 2 C for 24
hours.
Remove the specimen and wipe out any traces of water with a damp cloth and weigh the
specimen. Complete the weighing 3 minutes after the specimen has been removed from
water (M2). Water absorption, percent by mass, after 24-hour immersion in cold water is
given by the following formula:

M2 M1 * 100
M1

Weight
(dry) gm

Weight
(wet, after 24
hr)
Gm

3550

3825

7.746

3722

3942

5.910

3740

3953

5.695

Sample

AVERAGE

% of water
Absorption

6.450

5.2.2 COMPRESSIVE STRENGTH TEST :

APPARATUS:

Compression testing machine, measuring tape or scale, surface grinder, plywood sheets.
PROCEDURE:

Preparation of Sample :-

i.

Remove unevenness observed in the bed faces to provide two smooth and
parallel faces by grinding.

ii.

Immerse the sample in water at room temperature for 24 hours.

iii.

Prepare cement mortar (1:1) and fill the frog and all void in bed faces with
it.

iv.

Store the sample prepared in (iii) under damp jute bag for 3 days in clean
water.

v.

Remove and wipe out a trace of moisture.

vi.

Measure the area of two horizontal faces.

Testing :i.

Place the specimen with flat faces horizontal and mortar filled facing
upwards between two plywood sheets and centre carefully between plates
of testing machine.

ii.

Load is applied axially at a uniform rate 14 N/mm per minute till failure
occurs; Note the maximum load at failure.

CALCULATIONS:
2

Compressive Strength (N/mm ) =

OBSERVATION TABLE:

Sample

Dimension of Fly ash Bricks

Length
(mm)

Width
(mm)

Height
(mm)

Avg.
Area of
bed
surface
2
(mm )

Max
load at
failure
(KN)

Compressive
strength
2
(N/mm )

225

110

75

23000

118

5.153

225

110

75

22800

104

4.582

225

110

75

22800

132

5.815

AVERAGE

5.425
( approx
54.25
2
kgf/cm )

6. CONCLUSIONS:
In this chapter conclusions of the so far done-study/Experimental work of this project are given
. Following conclusions are given from the present study: There is an imperative need to
produce more building materials for various elements of construction and the role of
alternative and innovative options would come into sharp focus, considering the short supply,
increasing cost and energy and environment considerations for traditional and conventional
materials. The possibility of using innovative building materials and technologies, more so
covering waste material like Ifyash have been considered as a felt need. Series of institutional
support for land, for land, finance, regulatory, media, marketing support, testing support and
awareness creation would be needed and some of the existing initiatives would have to be
substantially strengthened, more importantly, entrepreneurship for the production of
appropriate flyash based walling, roofing and flooring materials including Portland Pozzolana
Cement and other cements to ad1ieve better strength, energy saving, conservation of natural
resources besides cost efficiency, would have to be increasingly supported and developed. Fly
ash utilization in the country has remained less than10% during the past 5 years and it might
take several years to reach the final goal of cent percent utilization. Every year nearly 70 million
tonnes of ash is producedin India, of which NTPC stations alone contribute to theextent of
about 22 million tonnes.

The results shows the FaL-G bricks are more safe,economical and having higher strength
compare toconventional bricks.According to case study the fly ash bricks with Conventional
masonry work have 28% saving in costwith common red brick and conventional masonrywork.
The masonry work with new technology Rat-Trap bond in fly ash bricks have 33% saving in cost
ascompared to common bricks. Further Fly ash bricks have many advantages like
Light weight
Economical
Environmental friendly
Saving of fertile land, pure water
More compressive strength
Use of wastage etc. and also
The compressive strength of bricks increases with lime proportion.
The bricks made under pressure has increased compressive strength according as the pressure
was applied

 As long as the percentage between lime and fly ash is unchanged, the change in soil
percentages does not affect compressive strength significantly.